A

PROJECT REPORT

ON
Pneumatic operated pick and place material

handling system

Submitted by

Ketan S patil (188135)

Yash P jadhav (198116)

Gaurav dhayde (188135)

Saurbh gojre (188113)

Under the guidance of

Shri. TG. Chavan sir

DEPARTMENT OF AUTOMOBILE ENGINNERING

GOVERNMENT POLYTECHNIC, NASHIK

(An autonomous institute of Govt. of Maharashtra)

ACADEMIC YEAR: 2020-2021

 Government Polytechnic, Nashik.
(An Autonomous Institute of Govt. of Maharashtra)

Department of Automobile Engineering

CERTIFICATE
This is to certify that the project report on “Pneumatic operated pick and place
material handling system” has been successfully completed by

Ketan patil (188135)

Yash P jadhav (198116)

Ghansham Jadhav (188135)

Saurabh gojre (188113)

Shri. T.G.Chavan External Examiner

(Project Guide)

Prof. T.G. Chavan Shri. D.P. Nathe

(Principal)
(Head of Department)

2
 ACKNOWLEDGEMENT
It gives us an immense pleasure to submit this project report on ‘pneumatic operated pick

and place material handling system’. We tried our level best to present this topic into compact

and to point framework.

We wish to express our sincere thank with profound gratitude to our guide Shri. T.G

chavan for his valuable guidance and constant encouragement without it would have been

impossible for us to present and complete this project successfully. We would like to extend our

sincere and true thank to our Head of Department Prof. T.G. Chavan. We are extremely grateful

to principal, Prof. D.P. Nathe. We thank all the staff members of the department for the co-

operation extended to us. Let us not forget to thank all our friends for their assistance and help.

It is our pleasant privilege to express our sincere gratitude to our beloved parents, without their

blessings we would not be here at this stage of our life. Finally, we also would like to thank to our

parents for their support, caring, blessing, motivation and understanding throughout this last year.

Their love and care kept us going in hardest times.

Above all, we thank Almighty for everything we have received in our life. Apologies to those

whose help is not acknowledged.

Ketan S patil (188135)

Yash P jadhav (198116)

Gaurav dhayde (188135)

Saurabh gojre ( 188113)

3
Sr.no Name of Topic Page no.
A COVER PAGE 1
B CERTIFICATE 2
C ACKNOWLEDGEMENT 3
D INDEX 4
E LIST OF FIGURES AND TABLES 6
F ABSTRACT 7
1) CHAPTER I
1.1 Introduction 8

1.2 Production of wheel 10

1.3 Materials and Methodology 12

2) CHAPTER II

2.1 Literature survey 13

3) CHAPTER III

3.1 Function of wheel rim 15

3.2 Classification of car wheel 15

3.3 Rim Nomenclature 19

4) CHAPTER IV

Theoretical Analysis 21

4.1 Specification of wheel rim 21

4.2 Properties of Materials 21

4.3 Moment of wheel rim 21

4.4 Bending Moment 22

4.5 Radial Endurance Limit 22

5) CHAPTER V

4
 5.1 Design Procedure of Wheel Rim in CATIA V5 23

6) CHAPTER VI

6.1 Analysis using ANSYS 26

6.2 Aluminium Alloys Wheel Rim 27

6.3 For Aluminium Alloys 30

6.4 For Structural Steel 31

7) CHAPTER VII

7.1 Future Scope 32

8) CHAPTER VIII

8.1 Conclusion 33

9) CHAPTER IX

9.1 References 34

5
 LIST OF FIGURES

Sr. No Image Name Page No

1) Steel Wheel 16
2) Alloy Wheel 17
3) Rim Terminology 19
4) Design of wheel rim (2D) in CATIA 23
5) 3D design of wheel rim. 23
6) Holes for bolts in rim. 24
7) Fillet Radios 24
8) Full Drawing of 3D wheel rim. 25
9) Conversion to SLDPRT To ANSYS file 25
10) Equivalent Stress & Maximum Principal Stress 27
generated on the Model 1-wheel rim
11) Equivalent Stress diagram for model 2 & Maximum Principal 28
Stress diagram for model 2 of wheel rim
12) Equivalent Stress & Maximum Principal Stress for Model 3 of 29
wheel rim
13) Mass or weight vs. Equivalent stress for the Aluminium wheel 30
rim
14) Mass or weight vs. Equivalent stress for the structural steel wheel 31
rim

LIST OF TABLES
1) Mass and Equivalent stress for Aluminium and Structural steel 30

6
 ABSTRACT

Moving materials utilize time and space. Material handling is a necessary, but wasteful and expensive

activity in manufacturing and distributing. Material handling is a specialized activity for a modern

manufacturing concern. It has been estimated that about 60-70% of the cost production is spent in material

handling activities. Insufficient material handling accounts for additional costs in two main ways: idle time

and cost of labor. Effective material handling solutions can reduce a production or distribution cost by

significant amounts. The technology of pneumatics has gained tremendous importance in the field of

workplace rationalization and automation from old-fashioned timber works and coal mines to modern machine

shops and space robots. Certain characteristics of compressed air have made this medium quite suitable for

used in modern manufacturing and production industries. The air is compressed in an air compressor and from

the compressor plant the flow medium is transmitted to the pneumatic cylinder through

a well laid pipe line system..

7
 CHAPTER I

1 INTRODUCTION

Effective material handling is the most important part of manufacturing and distributing

operations because without it, a final product cannot be turned into profit. The technology of

pneumatics has gained tremendous importance in the field of workplace rationalization and

automation from old-fashioned timber works and coal mines to modern machine shops and space

robots. Certain characteristics of compressed air have made this medium quite suitable for used in

modern manufacturing and production industries. Material handling an integrated system

involving such activities as moving, handling, storing and controlling of materials by means of

gravity, manual effort or power activated machinery Material handling is an important area of

concern in flexible manufacturing systems because more than 80 % of time that material spends

on a shop floor is spent either in waiting or in transportation, although both these activities are

non-value added activities. Comparing the source of operation hydraulic and pneumatic,

Pneumatic source having good response over hydraulic and gives safe and cost effective material

handling. Efficient material handling is needed for less congestion, timely delivery and reduced

idle time of machines due to no availability or accumulation of materials at workstations. Safe

handling of materials is important in a plant as it reduces wastage, breakage, loss and improves the

overall efficiency of plant. Hence with concern of major area in production field in order to

improve the product quality, productivity, improve the personnel effort, improve the efficiency of

plant and improve the safety the pneumatic based six axis material handling system select area.

8
 CHAPTER II

2.0 DESIGN METHODOLOGY

Methodology includes the method to achieve the final objectives of project. Following are some

method or sequence of activities used in project to achieve final objectives.

2.1 Material Handling System

Material handling is a necessary and significant component of any productive activity. It is something that

goes on in every plant all the time. Material handling means providing the right amount of the right material,

in the right condition, at the right place, at the right time, in the right position and for the right cost, by using

the right method. It is simply picking up, moving, and lying down of materials through manufacture. It applies

to the movement of raw materials, parts in process, finished goods, packing materials, and disposal of scraps.

In general, hundreds and thousands tons of materials are handled daily requiring the use of large amount of

manpower while the movement of materials takes place from one processing area to another or from one

department to another department of the plant. The cost of material handling contributes significantly to the

total cost of manufacturing. Handling and storing materials involve diverse operations such as hoisting tons of

steel with a crane; driving a truck loaded with concrete blocks; carrying bags or materials manually; and

stacking palletized bricks or other materials such as drums, barrels, kegs, and lumber.

9
 2.2 Pneumatics in Material Handling

Pneumatic systems usually operate at much lower pressure than hydraulic systems do, pneumatics

holds many advantages that make it more suitable for many applications. Because pneumatic pressures are

lower, components can be made of thinner and lighter weight materials, such as aluminum and engineered

plastics, whereas hydraulic components are generally made of steel and ductile or cast iron. Hydraulic systems

are often considered rigid, whereas pneumatic systems usually offer some cushioning, or “give.” Pneumatic

systems are generally simpler because air can be exhausted to the atmosphere, whereas hydraulic fluid usually

is routed back to a fluid reservoir. Pneumatics also holds advantages over electromechanical power transmission

methods. Electric motors are often limited by heat generation. Heat generation is usually not a concern with pneumatic

motors because the stream of compressed air running through them carries heat from them. Furthermore, because

pneumatic components require no electricity, they don’t need the bulky, heavy, and expensive explosion-proof

enclosures required by electric motors. In fact, even without special enclosures, electric motors are substantially larger

and heavier than pneumatic motors of equivalent power rating. Plus, if overloaded, pneumatic motors will simply stall

and not use any power. Electric motors, on the other hand, can overheat and burn out if overloaded. Moreover, torque,

force, and speed control with pneumatics often requires simple pressure- or flow-control valves, as opposed to more

expensive and complex electrical drive controls. And as with hydraulics, pneumatic actuators can instantly reverse

direction, whereas electromechanical components often rotate with high momentum, which can delay changes in

direction.

10
 CHAPTER III

3.1. Proposed System

The automation plays an important role in saving human effort in most of regular and frequently carried works.

The most common work is pick and place of jobs or work piece from source to desired position. Present day

industry turned towards computer based program automation as it increase the productivity and delivery of

end products. The inflexibility and hard automation is used in highly automated truck in the past have to led

used of automated arms which is capable of performing the variety of manufacturing function in a flexible

environment and at lower cost. The pick and place mechanical arm is human based controlled based system

that detection of object human detect presence of object and move the machine accordingly

The robot's manipulative arm is the mechanical unit. This mechanical unit is also comprised of a fabricated

structural frame with provisions for supporting mechanical linkage and joints, guides, actuators (linear or

rotary), control valves, and sensors. The physical dimensions, design, and weight carrying ability depend on

application requirements .It consist of following parameters.

11
• Work Envelop: The set of points Representing the maximum extent or reach of the robot arm or

working tool in all direction.

• Payload: The ability to carry, continuously and satisfactorily given maximum weight at a given speed.

• Velocity: The maximum speed at which the tip of a robot is capable of moving at full extension,

expressed in inches or millimeter per second.

• Cycle: Time it takes for the robot to complete one cycle of picking up a given object at a given height

, moving it to a given distance lowering it, releasing it, and returning to the starting point.

• Accuracy: A Robot’s Ability to position the end effecter at a specified point in space upon receiving.

• Repeatability: The ability of a robot to return consistency to a previously having attained that position.

• Resolution: The smallest incremental change in position that it make or its control system can measure.

• The manipulator: Which is the robot’s, consists of segments jointed together with axes capable of

motion in various direction allowing the robot to perform work. The end effectors which is a gripper

tool, special devices, or fixture attached to the robot’s arm actually performs the work.

12
 CHAPTER IV

4.0 PROBLEM DEFINITION

In every manufacturing unit the components are manufactured far away from the assembly unit so that,

the main task is components should be present in right time, at right place, in right quantity, as every

manufacturing system enhancing has motive to reduce inventory. The problems were, damage to the treatment

provided to components during transportation, damage to the physical structure of components during handling

which may create delay in assembly unit and directly on productivity. This project deals with designing of

material handling equipment for better and organized material flow which will also have ergonomics

consideration. The problems arising are as follow

1. Damage of components in transportation from manufacturing unit to assembly unit. Damage to the

paint and treatment given to the components.

2. Damage to the component, may lead to problem in assembly also More time is required in material

handling, this may lead to delay in the flow of lean manufacturing To ensure that the right material in the right

amount is safely delivered to desired place at right time with minimum cost and control of material by using

pneumatic based six axis material handling equipment.

13
 CHAPTER V

5.0 Material selection

Material selected: Plain carbon steel Material grade:

30C8 Chemical composition:

1 Mechanical Properties : Tensile strength (Sut) = 500 N/mm2 Yield strength (Syt) = 400 N/mm2

Hardness (H) = 179 HB Elongation (e) = 21% 4.2 Frame section Fabrication is the process used to manufacture

steelwork components that will, when assembled and joined, form a complete frame. The frame generally uses

readily available standard sections that are purchased from the steelmaker or steel stockholder, together with

such items as protective coatings and bolts from other specialist suppliers. Wide range of section shapes and

sizes are readily available. Different sections are used in the main body of equipment because of their

difference in loading conditions. Sections used in equipment are C-sections, L-section, Square tube, Circular

tube. 4.3 Selection of standard parts Design process is all about standardizing the element as much as possible.

Standardization is the process of implementing and developing technical standards based on the consensus of

different parties that includes firms, users, interest groups, standards organizations and governments.

Standardization can help to maximize compatibility, interchangeability, safety, repeatability, or quality.

The standard parts such as pneumatic cylinder, wheels and direction control valve selected during the

design and manufacturing of equipment with their specification are as follows

2 Selection of pneumatic cylinders the parameter such as Cylinder thrust, Air consumption, .Piston velocity,

and type of mounting. The cylinder thrust is a function of Cylinder thrust in N. (f), Diameter of piston in mm

(d), Operating air pressure in bar (P), frictional resistance, etc. The air consumption data for a cylinder is

required to estimate the compressor capacity. The calculations include air consumption during forward as well

as return stroke. The free air consumption for forward stroke is calculated as follows: Free air consumption =
14
piston area x (operating pressure + 1.013) x stroke The free air consumption for return stroke is also calculated

similarly and added to arrive at total free air consumption of cylinder during one complete cycle Factors

governing the piston velocity are: the operating pressure, opposing forces, inside diameter and length of the

air line between the control valve and cylinder and the size of the control valve. The piston velocity may be

increased or decreased with the help of a quick exhaust valve or flow control valve respectively. The average

piston speed at no – load is between 100 – 500mm/ sec. Depending on the frequency of operation and the

speed required, proper type and size of valve needs to be selected. We use three types of cylinder in equipment

are as follow: Cylinder having borne diameter as 20mm and stroke length 75mm is used to revolve or rotate

the rack and pinion. The piston end is connected to rack with which it can travel in longitudinal direction and

results to rotate the pinion and as whole vertical arm is rotate along with actuators. The next cylinder with the

specification as 50mm bore diameter and 100mm as stroke length is used to list the vertical arm. We select

this cylinder as having maximum capacity so as to whole weight about (5 to 8 kg) is to be carried by this

vertical arm. Next cylinder is 50 mm bore diameter and 50 mm stroke length. The cylinder is used to carry the

horizontal arm weight which can inclined at an angle of 30° to 45°. Hence arm can be lift up and down as per

the requirement. Next cylinder is used for controlling the motion of final arm and also for controlling or

actuating the gripper motion of 25 mm bore diameter and 50 mm stroke length.

3 Calculations

Gear ratio (G) = 1.5 No of teeth on pinion as 60 > 18 (to avoid interference) [10] Z1 = 60 Therefore, G= Z2

/ Z1 Hence Z2 = 90 D=55 mm R=27.5 mm Solution: m= 5L3.14=1.59=2 m =2 mm Least pressure angle to

avoid interference: Let, Φ=least pressure angle to avoid interference m =rsin2φ 2=27.5sin2φ Φ=15.634°(14°to

20°) Length of the arc of contact= 13 mm Length of the arc of contact =13.48 mm Pc= πd/t =π*55/60 =2.87

mm Therefore, The no. of pairs of teeth in contact= Length of arc /circular pitch =13.48 / 2.87 = 4.69 = 5 So

minimum no. of teeth in contact is 5 Power required We know that pressure in the system System= 0.8Mpa or

8 bar System= F/A ( cylinder selected 20 × 75 ) F = 251.32 N Also P = F×V V = 6.28 m/s Hence, P =

251.32×6.28 = 1.57 Kw and Mt = = 249.87 N-m Tangential force act on pinion Pt = 9086.18 N Radial force act on

pinion PR= Ptahα =3307 N Addendum =hf=m=2mm Dedendum(hf) =1.25 m =2.5mm Clearance(C)= 0.25×m =0.5mm
15
Working Depth (hk)=2m=4mm Whole depth (h)=2.25m=2.25×2=4.5mm Tooth thickness(s) =1.57m=3.1416mm Tooth

space=1.57 m=3.1416mm Fillet radius=0.4 m=0.8 mm Pneumatic cylinder Double acting pneumatic cylinder for given

telescopic action to two arms first telescopic length is 100mm, hence we select the cylinder having specification of

50×100 Volume of air exhaust (v) = l × a1 = 1.96×10-4 m3 Out stroke force (F) = P × a1 = 1568 N Effective area (A) =

a1- a2 = 5.02×10-5 m2 In stroke force (f) = P×A = 1527.84 N Total load on cylinder is equal to total set up weight

including arm and upper cylinder = 10 Kg Therefore 1527.84 N > 98.1 N Double acting pneumatic cylinder for rotary

movement between arms for the angular movement between the two arms we select the cylinder having specification

25×50 similarly, volume of air exhaust (v) = l × a1 =2.35×10-5 m3 Outstroke force (F) = P × a1 = 251.2 N Effective

area (A) = a1- a2 = 2.63×10-4 m2 Instroke force (f) = P×A = 210.4 N

Load on the cylinder is 5 kg, hence 210.4 N > 49 N, cylinder is safe.

16
 CHAPTER VI

CONCLUSIONS

Low weight system. The system weight minimized at every point and reduce the material required

hence achieve low cost automation. Overall manufacturing time by designing efficient material movement

reducing. Production rate increases and manufacturing time is reduced as the material flow is continuous and

efficient Creation and encouragement of safe and hazard-free work condition. Safety must be given first

priority and proper measures should be taken to improve safety conditions. The parts are placed such that it

considers human capabilities and limitations which will reduce human effort while loading and unloading. The

cost of equipment will be reduced by 15% of existing equipment and become for flexible than existing

pneumatic based material handling system. System provides proper control over the material without any

damage or mishandling which interns leads to increase in quality of the material. Facilitate the reduction in

material damage as to improve quality. Easy to use, the system easy to manufactured so that simple operating

possible and no skilled labor required for operation. This will result in less complex system.

17
 CHAPTER VII

FUTURE SCOPE

Pneumatic based materials handling equipment’s are used Materials handling problems involve surveys,

plant and equipment layouts, routing, packaging and storage of materials. It is also used for handling the bulk

material such as gases, liquid semi-liquid etc. It is also used in heavy construction projects, there is now a

choice of special methods and equipment’s of materials handling. It influences the civil engineers in project

planning. For the extraction, handling and transportation of coal and ore in case of both underground mines and open

pit operation Cost of extracting the materials has been reduced to the minimum. for handling of material such as fuel and

ash. The design of many processing machines is influenced by the need for integrating various material handling features

or attachments to modern machine mechanisms. The automotive engineer develops trucks and trailer as efficient

materials handling vehicles, designed for speedy loading and unloading, ensure cargo is secured properly, and safe

transportation of a variety of materials.

18
 CHAPTER VIII

ACKNOWLEDGEMENT

While presenting this project, we are glad to convey our thanks to the people who guided us and help us at

every stage of our project. We deeply acknowledge the support of our Head of Department Prof. Bhamre

V.G. for his valuable input and constant guidance in successful completion of our project. We also thank our

project guide Prof. Londhe V.D. and giving their valuable time and guiding us throughout in the

development of our project.

19
 CHAPTER IX
REFERENCES

[1] Kaustubh V. Wankhade and Dr. N. A. Wankhade, “Design and analysis of transfer trolley for material

handling” a review, International Journal of Application or Innovation in Engineering & Management

(IJAIEM), Volume 4, Issue 2, February 2015, pp. 029-033.

[2] Wilson R. Nyemba, Charles Mbohwa, and Lloyd E. N. Nyemba, “Optimization of a plant layout and

materials handling system for a furniture manufacturing company”, Proceedings of the World Congress on

Engineering 2016 Vol II WCE 2016, June 29-July 1, 2016, London, U.K.

[3] Jolanta B. Krolczyk, Grzegorz M. Krolczyk, Stanislaw Legutko, Jerzy Napiorkowski, Sergej Hloch,

Joachim Foltys, Ewelina Tama, “Material Flow Optimization – a case study in automotive industry”, pp. 1330-

3651.

[4] Raghunathan Rajesh, Rakesh V Babu, Saran Ramachandran, “Ergonomic redesign of a material handling

worksystem in a manufacturing plant” pp. 2319 – 8753. [5] Guilherme Bergmann Borges Vieira, Giovana

Savitri Pasa, Maria Beatriz Nunes do Oliveira Borsa, Gabriel Sperandio Milan, Alberto Pandolfo, “Materials

handling management” pp. 1984-3046.

20